Utilising a hybrid DMAIC/TAM model to optimise annual maintenance shutdown performance in the dairy industry: a case study

IF 3.8 2区 工程技术 Q2 ENGINEERING, INDUSTRIAL International Journal of Lean Six Sigma Pub Date : 2023-12-25 DOI:10.1108/ijlss-05-2023-0083
Anna Trubetskaya, Alan Ryan, Daryl John Powell, Connor Moore
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Abstract

Purpose Output from the Irish Dairy Industry has grown rapidly since the abolition of quotas in 2015, with processors investing heavily in capacity expansion to deal with the extra milk volumes. Further capacity gains may be achieved by extending the processing season into the winter, a key enabler for which being the reduction of duration of the winter maintenance overhaul period. This paper aims to investigate if Lean Six Sigma tools and techniques can be used to enhance operational maintenance performance, thereby releasing additional processing capacity. Design/methodology/approach Combining the Six-Sigma Define, Measure, Analyse, Improve, Control (DMAIC) methodology and the structured approach of Turnaround Maintenance (TAM) widely used in process industries creates a novel hybrid model that promises substantial improvement in maintenance overhaul execution. This paper presents a case study applying the DMAIC/TAM model to Ireland’s largest dairy processing site to optimise the annual maintenance shutdown. The objective was to deliver a 30% reduction in the duration of the overhaul, enabling an extension of the processing season. Findings Application of the DMAIC/TAM hybrid resulted in process enhancements, employee engagement and a clear roadmap for the operations team. Project goals were delivered, and original objectives exceeded, resulting in €8.9m additional value to the business and a reduction of 36% in the duration of the overhaul. Practical implications The results demonstrate that the model provides a structure that promotes systematic working and a continuous improvement focus that can have substantial benefits for wider industry. Opportunities for further model refinement were identified and will enhance performance in subsequent overhauls. Originality/value To the best of the authors’ knowledge, this is the first time that the structure and tools of DMAIC and TAM have been combined into a hybrid methodology and applied in an Irish industrial setting.
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利用 DMAIC/TAM 混合模型优化乳制品行业的年度停机维护绩效:案例研究
目的自 2015 年取消配额以来,爱尔兰乳制品行业的产量迅速增长,加工商们投入巨资扩大产能,以应对额外的牛奶产量。将加工季节延长至冬季可进一步提高产能,而缩短冬季维护检修期是实现这一目标的关键因素。本文旨在研究是否可以使用精益六西格玛工具和技术来提高运行维护绩效,从而释放额外的加工能力。将六西格玛定义、测量、分析、改进、控制(DMAIC)方法与广泛应用于加工行业的周转维护(TAM)结构化方法相结合,创造出一种新颖的混合模型,有望大幅改善维护检修的执行情况。本文介绍了一项案例研究,该研究将 DMAIC/TAM 模型应用于爱尔兰最大的乳品加工厂,以优化年度停机维护。研究结果DMAIC/TAM 混合模型的应用为运营团队带来了流程改进、员工参与和清晰的路线图。结果表明,该模型提供了一个促进系统化工作和持续改进的结构,可为整个行业带来巨大利益。据作者所知,这是首次将 DMAIC 和 TAM 的结构和工具结合成一种混合方法,并应用于爱尔兰的工业环境中。
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来源期刊
International Journal of Lean Six Sigma
International Journal of Lean Six Sigma Engineering-Industrial and Manufacturing Engineering
CiteScore
8.90
自引率
15.00%
发文量
46
期刊介绍: Launched in 2010, International Journal of Lean Six Sigma publishes original, empirical and review papers, case studies and theoretical frameworks or models related to Lean and Six Sigma methodologies. High quality submissions are sought from academics, researchers, practitioners and leading management consultants from around the world. Research, case studies and examples can be cited from manufacturing, service and public sectors. This includes manufacturing, health, financial services, local government, education, professional services, IT Services, transport, etc.
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